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stamixco……………….mix it up
SMB Extrusion Melt Blender
INTRODUCTION
StaMixCo manufacturers all three commercially proven static Operating Benefits
mixer designs used for extrusion service (see page 3). As with A static mixer creates outstanding homogenization of the polymer
most pieces of process equipment, each static mixer design has melt at the face of the die. With the polymer melt being
specific advantages and disadvantages that make it more or less homogeneous with regard to temperature, viscosity,
suitable for a specific application and installation. colorant/additive distribution and elimination of wall-creep
material, the following operating benefits are realized:
The Static Mixer Melt Blender (Figure #1) is installed just in front
of the extruder die. It is installed as the last piece of equipment y Reduction of color additives with comparable extrudate color
to correct all irregularities created by the extruder screw, empty density.
piping and downstream auxiliary equipment such as screen y Even thickness across the entire extrudate width.
changer and gear pump. In some applications such as multi- y Streak-free product.
layer film, small diameter mixing elements are installed within the y Improved quality when using regrind material.
die flow channels, y Foam cell size and cell distribution uniformity.
y Improved surface quality
The Static Mixer Melt Blender contains no moving parts. Molten y Improved mechanical characteristics.
polymer, driven by the screw, flows through the static mixer as it y Rapid color change-over.
enters the die. The static mixer homogenizes the melt in a
remarkably short length by continuously dividing and recombining
material flowing through its geometric structure. In virtually all
applications, the Melt Blender can accommodate the length and Extrusion Applications
pressure drop constraints of the extrusion system. Static Mixers are used in most extrusion applications including
the following:
y Sheet y Extrusion Blow Molding
Process Improvements y Blown Film y Rod & Tubing
The fundamental process improvement that a static mixer y Foam sheet y Wire & Cable
creates is the optimization of conditions of the molten polymer at y Profile y Coatings
the face of the die. This allows for an improved extruded y Co-Extrusion y Cereals and other foods
product. The process improvements are: y Pipe y Fibers & Monofilaments
y Radial temperature gradients are virtually eliminated.
y Viscosity gradients are virtually eliminated.
y Composition gradients are virtually eliminated with regards to
colorant, chemical additives, fillers and regrind.
y Stagnant polymer wall-creep material is incorporated into the
bulk polymer stream.
Figure #1: The Static Mixer Melt Blender is installed just in front of the die to homogenize the polymer melt.
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ITEMS
OF
COMPARISON
High Temperature
Polymer Melt (THT)
Low Temperature
Polymer Melt (TLT)
Figure #12: Blue and White resin (1:1 volumetric ratio) is pumped through a total of sixteen (16 -SMB-R mixing elements, allowed to
harden and cross-sectional cuts are made at the outlet of each mixing element. Notice how quickly the streams are mixed and that
adjacent mixing element blades are oriented 90o to assure mixing over the entire pipe cross-section. Depending on the application, the
number of mixing elements required normally range from four (4) mixing elements (L/D = ~2) for mild thermal homogenization
requirements; the standard eight (8) mixing elements for most compositional and thermal homogenization requirements (L/D = ~4.0);
and twelve (12) mixing elements (L/D = ~6) for critical applications requiring a very high degree of mixing.
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SMB-R Static Mixer Sizing
The proper size SMB-R Melt Blender for a specific application is The mixing elements easily disassemble from one-another for
a function of the available pressure drop; degree of mixing inspection or cleaning as shown in Figure #10 and #12.
required and polymer flow rate and viscosity at the operating
conditions. For most applications, Table #1 provides a For pressure drop critical applications; the processing of specialty
conservative estimate of required static mixer size based on engineering plastics we are not familiar with; or for mixer
extruder screw diameter and high or low viscosity polymer being installations inside of die blocks, we have the know-how to
processed. properly size the mixing unit. To perform the necessary design
calculations, polymer rheology information (shear rate vs.
The standard SMB-R Extrusion Melt Blender contains viscosity at operating conditions) is required. If you or we feel
8-mixing elements as shown in Figures #13 and #14 with key that your application requires special calculations, we will contact
dimensions shown in Table #1. The mixing elements are made your resin supplier with your permission and manage the effort of
of heat treated high strength 17-4 PH stainless steel material. obtaining the necessary technical information to perform the
detailed calculations.
Figure #13: Dimensions of eight (8) SMB-R mixing elements. Figure #14: Complete SMB-R Melt Blender in Housing.
See also Figure #10, #11 and #12 for visualization.
Table #1: Key Sizing and Dimensional Parameters for eight (8) standard SMB-R Mixing Elements as shown in Figures #13 & #14.
Extruder Screw Diameter
Melt Blender Mixing Elements1) Housing
(mm)
LTOT
High Viscosity Low Viscosity I.D. O.D.2) LME
Model Number 8 Mixing Bore (mm)
Polymer Polymer (mm) (mm) (mm)
Elements
10 mm 20 mm SMB-R12/18-8 12 mm 18 mm 8.0 64 18
10 mm 25 mm SMB-R18/26-8 18 mm 26 mm 11.2 90 26
25 mm 30 mm SMB-R20/28-8 20 mm 28 mm 12.5 100 28
25 mm 35 mm SMB-R22/30-8 22 mm 30 mm 13.5 108 30
25 mm 45 mm SMB-R27/35-8 27 mm 35 mm 16.5 132 35
35 mm 50 mm SMB-R33/42-8 33 mm 42 mm 20.0 160 42
50 mm 60 mm SMB-R40/50-8 40 mm 50 mm 24.0 192 50
60 mm 75 mm SMB-R52/60-8 52 mm 60 mm 30.0 240 60
75 mm 100 mm SMB-R66/75-8 66 mm 75 mm 37.5 300 75
90 mm 120 mm SMB-R80/90-8 80 mm 90 mm 45.0 360 90
120 mm 150 mm SMB-R102/115-8 102 mm 115 mm 57.5 460 115
150 mm 200 mm SMB-R126/140-8 126 mm 140 mm 68.8 560 140
200 mm 240 mm SMB-R153/175-8 153 mm 175 mm 85.5 684 175
230 mm 280 mm SMB-R175/200-8 175 mm 200 mm 95.5 764 200
275 mm 320 mm SMB-R200/225-8 200 mm 225 mm 115 920 225
Tolerances - f7 0/-0.1 0/-0.8 H7
1)
All sizes in stock for next day shipment
2)
The O.D. of the mixing elements can be adjusted.
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* StaMixCo is not a distributor of, authorized by or affiliated with Sulzer Chemtech. SMX is a brand of Sulzer Chemtech.
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SMB-GX Static Mixer Sizing
The proper size SMB-GX Melt Blender for a specific application For pressure drop critical applications; the processing of specialty
is a function of the available pressure drop; degree of mixing engineering plastics we are not familiar with; or for mixer
required and polymer flow rate and viscosity at the operating installations inside of die blocks, we have the know-how to
conditions. For most applications, a conservative estimate of properly size the mixing unit. To perform the necessary design
required static mixer size is matching it to the extruder screw calculations, polymer rheology information (shear rate vs.
diameter. viscosity at operating conditions) is required. If you or we feel
that your application requires special calculations, we will contact
The standard SMB-GX Extrusion Melt Blender contains your resin supplier with your permission and manage the effort of
4-mixing elements as shown in Figures #18 with key dimensions obtaining the necessary technical information to perform the
shown in Table #2. The mixing element sizes are made of heat detailed calculations.
treated high strength 17-4 PH stainless steel material.
Figure #18: Dimensions of four (4) SMB-GX mixing elements (see Table #2)
Table #2: Key dimensions of four (4) Standard SMB-GX Mixing Elements as shown in Figure #18
1)
Bore Size Melt Blender Mixing Elements Support Ring
Inch Millimeter
D LME LTOT DR
1)
LR
1)
Sizing Sizing Model Number 4-Mixing Elements
(inch) (mm) (mm / inch) (mm / inch) (mm / inch) (mm / inch)
(mm / inch)
10 mm SMB-GX-10-4 9.8 mm 9.8 mm 42 mm 14 mm 15 mm
13 mm SMB-GX-13-4 12.4 mm 12.4 mm 52 mm 17 mm 15 mm
16 mm SMB-GX-16-4 15.8 mm 15.8 mm 67 mm 21 mm 16 mm
21 mm SMB-GX-21-4 20.2 mm 20.2 mm 84 mm 26 mm 20 mm
27 mm SMB-GX-27-4 26.8 mm 26.8 mm 110 mm 33 mm 23 mm
1 1/2” SMB-GX-1.5-4 1.47” 1.47”: 6.125” 2.0” 1.0”
48 mm SMB-GX-48-4 41.3 mm 41.3 mm 167.0 mm 48.0 mm 30 mm
2” SMB-GX-2.0-4 1.97” 1.97” 8,125” 2.5” 1.25”
53 mm SMB-GX-53-4 51.8 mm 51.8 mm 210 mm 60 mm 37 mm
2 1/2” SMB-GX-2.5-4 2.47” 2.47” 10.125” 3.0” 1.75”
68 mm SMB-GX-68-4 66.5 mm 66.5 mm 270 mm 75 mm 45 mm
3” SMB-GX-3.0-4 2.97” 2.97 12.125” 3.5” 2.0”
82 mm SMB-GX-82-4 80.2 mm 80.2 mm 328 mm 90 mm 53 mm
3 1/2” SMB-GX-3.5-4 3.47” 3.47” 14.125 4.0” 2.25”
4” SMB-GX-4.0-4 3.97” 3.97” 16.25” 4.5” 2.50”
103 mm SMB-GX-103-4 101.5 mm 101.5 mm 412 mm 115 mm 65 mm
4 1/2” SMB-GX-4.5-4 4.44” 4.44” 18.0” 5.0” 2.75”
5” SMB-GX-5.0-4 4.94” 4.94” 20.0” 5.625” 3.0”
128 mm SMB-GX-128-4 126.2 mm 126.2 mm 512 mm 140 mm 80 mm
6” SMB-GX-6.0-4 5.94” 5.94” 24.0” 6.750” 3.50”
155 mm SMB-GX-155-4 153.5 mm 153.5 mm 625 mm 175 mm 98 mm
175 mm SMB-GX-175-4 173.5 mm 173.5 mm 720 mm 200 mm 120 mm
200 mm SMB-GX-200-4 198.5 mm 198.5 mm 820 mm 230 mm 135 mm
8” SMB-GX-8.0-4 7.94” 7.94” 33.0” 9.0” 5.5”
1)
Support Ring Outside Diameter (DR) and Length (LR ) can be supplied in any configuration.
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Figure #20: Blue and white viscous resin (1:1 volumetric ratio) is pumped through six (6) SMB-H static mixing elements, allowed to
harden and cross-sectional cuts are made at the outlet of each mixing element. The SMB-H static mixer is considered a low
performance mixing device of long length and is therefore used for non-demanding applications. Compare the SHB-H low degree of
mixing to the high performance SMB-R (Figure #12) and SMB-GX (Figure #17) static mixers. The SMB-H however has a very low
pressure drop that allows it to be used in smaller diameters for the same extruder screw size.
* StaMixCo is not a distributor of, authorized by or affiliated with Kenics Corporation. Thermogenizer is a brand of Kenics Corporation.
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Figure #21: SMB-H Helical Melt Blender with 6-Elements and L/D = 1.5 twist.
Table #3: Key dimensions of SMB-H Helical Melt Blender with 6-Mixing Elements of L/D=1.5 twist.
Mixing Elements 1)
Bore Size Melt Blender Support Ring
D LME LTOT 1) 1)
inches Model Number 6-Mixing Elements DR LR
inches inches inches inches
inches
3/4”” SMB-H-0.75-6x1.5 0.65” 1.125” 6.875” 1.125” 0.75”
1” SMB-H-1.0-6x1.5 0.9” 1.5” 9.125” 1.60” 0.75”
1 1/2” SMB-H-1.5-6x1.5 1.4” 2.25” 13.625” 2.25” 1.125”
2” SMB-H-2.0-6x1.5 1.9” 3.0” 18.125” 3.0” 1.5”
2 1/2” SMB-H-2.5-6x1.5 2.4” 3.75” 22.625” 4.25” 2.25”
Figure #22: SMB-H Helical Melt Blender with 9-Elements and L/D = 1 twist.
Table #3: Key dimensions of SMB-H Helical Melt Blender with 9-Mixing Elements of L/D=1 twist.
Mixing Elements 1)
Bore Size Melt Blender Support Ring
D LME LTOT 1) 1)
inches Model Number 6-Mixing Elements DR LR
inches inches inches inches
inches
3/4”” SMB-H-0.75-6x1.5 0.65” 1.125” 6.875” 1.125” 0.75”
1” SMB-H-1.0-6x1.5 0.9” 1.5” 9.125” 1.60” 0.75”
1 1/2” SMB-H-1.5-6x1.5 1.4” 2.25” 13.625” 2.25” 1.125”
2” SMB-H-2.0-6x1.5 1.9” 3.0” 18.125” 3.0” 1.5”
2 1/2” SMB-H-2.5-6x1.5 2.4” 3.75” 22.625” 4.25” 2.25”
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Note: We believe the information contained in this brochure is correct. However, the information is not to be construed as implying any warranty or guarantee of
performance. We reserve the right to modify the design and construction of our products based on new findings and developments.
© 2007 StaMixCo LLC SMB-3.1 (2/9/07)